Research On Single Point Diamond Turning Technology For Complex Surface

With the development of optical system,the requirement for the shape of optical surface becomes more and more complex.The traditional planar and spherical shapes can not meet the requirement of the existing optical system.Complex surfaces show more and more important value and application prospects in optical systems because of their unique advantages.They are applied more and more widely and need more and more urgently.Some optical systems with special imaging effects can only be realized by using complex surface optical parts or complex structures.At the same time,in the face of the increasing requirements for the processing accuracy of optical components,the increasingly complex surface of parts and the diversified development trend of material characteristics,the traditional processing technology has been difficult or completely unable to meet its high-efficiency and high-precision processing,especially the processing of parts with complex surface and micro-structure complex characteristics needs new processing methods and technologies.Under the strong impetus of development demand,ultra-precision machining technology has been continuously innovating and breaking through.At present,single point diamond turning technology is one of the most effective and economical methods for manufacturing optical components.In some cases,it is even the only method.Its role in optical surface processing will continue to expand.Precision CNC turning technology of single point diamond,which is characterized by processing infrared optical elements of crystal type,plays an important role in military optical system.Therefore,the study of single point diamond precision turning complex surface technology has broad application prospects and practical application value.In this paper,taking the single point diamond turning of typical complex surface as an example,the turning principle and quality control of turning surface are studied,mainly including the following aspects.1.The general turning method and principle of single point diamond are studied.Fresnel diffraction surface is designed by analytic method.The factors affecting the turning surface quality are analyzed.The surface error compensation technology is proposed.The surface roughness model of turning is established and revised.According to the relationship between tool parameters and turning surface quality,the sources of diffraction surface errors are analyzed to guide the rational selection of tool parameters.It is verified by turning Fresnel diffraction surface.2.A method of turning micro pyramid arrays with flying cutter is proposed.The model of flying cutter turning is established,and the relationship between burrs generated by turning and processing parameters is studied.According to the relationship model between turning parameters and the size of micro-structure unit,the influence of repeated positioning error of machine tool on the turning effect of microV groove array is simulated and analyzed,and the optimized burr process is put forward.The micro-pyramid array structure with better surface quality was finally obtained by optimizing the process through experiments.3.Analyzed the fast tool servo turning mode and processing principle,study the tool path planning algorithm and tool radius compensation method.The factors affecting the surface quality of fast tool servo turning are analyzed,and the optimization of tool path planning algorithm is proposed,which is verified by the experiment of fast tool servo turning spherical array.4.Study the slow-tool servo turning technology,establish the transformation relationship between coordinate systems,simulate and calculate the influence of tool alignment error on the inclined plane of slow-tool servo turning,study the PVT interpolation algorithm of slow-tool servo turning,and validate the accuracy of the interpolation algorithm with sinusoidal wave as an example.The off-axis paraboloid is machined by slow tool servo turning to verify the ability of slow tool servo turning.5.Analyzing the influence of turning cutter grain on optical system,the ion beam modification is proposed to remove the residual cutter grain on turning surface and improve the surface quality.The theoretical model of deterministic optical processing is established,and the ability of ion beam modification is analyzed.The experiment proves that ion beam can improve the turning surface quality.